Gaiter Face Mask Pattern – Easy, Fast, & Versatile!

Instructions

Step 1: Get my free easy Gaiter face mask pattern

My free DIY gaiter face mask pattern comes in several formats. You can get a printable PDF for cutting by hand, or an SVG cut file for cutting with a Cricut or another cutting machine. Download Design #223 which is the DIY gaiter face mask pattern, from my free resource library (get the password to the library in the form at the bottom of this post), or click here!

Here's what the Gaiter Face Mask PDF pattern looks like printed out:

Here’s what the gaiter face mask SVG cut file will look like once uploaded to Cricut Design Space (the top three are for youth, the bottom four are for adults, and the two gray rectangles are filter pockets in two sizes): 

Tip: If you’re not sure how to upload an SVG cut file to Cricut Design Space, watch this helpful video training series I made. If you’re on an iPhone or iPad, here’s how to download and upload SVG files to the Cricut Design Space app.

Step 2: Cut out your DIY Gaiter Face mask pattern pieces from fabric

I recommend you use two different colors and/or patterns of knit fabric to make your gaiter face mask, that way you always know which side is the outside and which is the inside. You don't want to accidentally put the outside layer against your mouth. For this tutorial, I'm using a blue patterned knit as the outside layer and a pink solid knit as the inner layer.

Tip: Pay attention to the fabric grain and pattern direction noted on the printed pattern.

If you're cutting the gaiter mask by hand, just print out the printable PDF, cut out each pattern piece as directed, and use it to cut your fabric. Note that your fabric is folded in quarters before cutting each layer.

Note: I'm using DIY pattern weights to hold my pattern in place while I cut my fabric in the above photo.

Tip: If you plan to make a LOT of these gaiter face masks, print out your patterns on cardstock for tracing!

Be sure to cut two layers of fabric!

If you're cutting this gaiter face mask on a Cricut Maker: Place your fabric right side down on a pink FabricGrip cutting mat. Load your rotary blade and fabric marker into your Cricut machine, load your mat, and press the flashing button to begin your cut. 

If you're cutting this gaiter face mask on a Cricut Explore, it's probably more trouble than it is worth because these are really just rectangles. But if you want to do it, see this tutorial on how to cut fabric on a Cricut Explore.

Step 3: (Optional) Make the Filter Pocket

If you want to add the filter pocket, cut out a piece of fabric with the filter pocket pattern.

Take the layer of fabric that will be your inside layer and fold it in half the long way. Mark that center point with a pin.

Now fold your filter pocket in half the long way and mark its center point with a pin.

Line up the inside layer and the filter pocket along their center points, one inch from the edge. Make sure the wrong side of your pocket is against the right side of your inner layer. Pin in place.

Sew the filter pocket to the inside layer of the gaiter face mask along the two edges and bottom at 1/4" seam allowance with a straight stitch, leaving the top opening (the side closest to the edge) open. Be sure to do a backstitch at the start and end of your line of sewing to keep your pocket secure.

Step 4: Pin and sew the long sides together

Place your inner layer on top of the outer layer for your gaiter face mask. Make sure the right sides (the side with a design on it if you have any) are facing each other. If you added a pocket in step 3, your pocket side should be facing your outer layer. Pin in place.

Fold your two layers in half the long way (with the pocket at the top, if you have one) and mark the top center point of your gaiter face mask, then measure out about 3" on either side of this center point and pin again. Put two more pins immediately next to those last two pins, then remove the center pin entirely.

Starting at one long end along the side with your double pins, sew with a zig zag stitch (or serge with your serger) from the corner until you get to where your double pins are and stop. Move your fabric up and resume sewing from the second set of double pins to the bottom edge of your fabric.

Important: You MUST use a zig-zag stitch (or serger) when sewing fabric with stretch. A single straight stitch doesn't allow flexibility for the fabric to stretch and the seams will break when stretched.

Note: I am using a using a basic sewing machine for this project, so my stitches may appear slightly different than yours if you are using a serger. The directions and results are the same, though.

Sew the other long side all the way from beginning to end with a zig zag stitch or serger. You should be left with a long tube with both short ends still open. Remove the pins.

Step 5: Sew your gaiter face mask tube together

Once both sides are sewn, stick your arm through the long tube and pull the farthest short side with raw edges INSIDE the tube to meet the other short side raw edge.

Your ends should meet up, creating a fold with the right sides of your fabric still facing the insides. You should still have a tube, just a shorter one.

Match the seams together, and pin along the outside edge.

Still using the zig-zag stitch, sew all around the ends until you get to your beginning stitch, making sure not to sew all four layers together. You're only sewing two layers together. You should still have a tube you can put your arm through when you're done.

Step 6: Turn your gaiter face mask right side out

After you've sewn all your edges together, find the holes you left in the top edge in step 5 in making your gaiter face mask. It may look a little like rabbit ears.

Start pulling your fabric through one of these holes (it doesn't matter which one) to turn your fabric layers right side out.

Make sure the layer you intended to be on the outside of your DIY gaiter face mask is the layer that is facing outward when you're done.

Once your fabric is right side out, it's time to close up the hole you used to turn this right side out. If you want to include a nose guard wire, now is the time -- just cut 4" of wire, fold in the ends so the wire doesn't poke through the fabric, and tuck the wire under the edge of one of the seams in the hole of your gaiter face mask.

Either way, I recommend you pin it in place.

Now sew the hole closed with either a zig zag stitch or a straight stitch.

Congratulations! You made an easy DIY gaiter face mask!!